Sensorized covering for an industrial device

ABSTRACT

A sensorized covering, prearranged for covering at least part of a movable structure of an automated device. The sensorized covering is useful for sensing an actual impact or anticipating an imminent impact to the automated device. The sensorized covering includes one or more covering modules wherein each covering module may include contact sensors and/or proximity sensors, a loading bearing structure and/or controls. The individual sensorized modules may be independently connected or controlled, or connected together and collectively controlled. Examples of the automated device my include a movable robots or an automated guided vehicles (AGVs).

FIELD OF INVENTION

The present invention relates to automated devices used in the sector ofindustrial production and has been developed with particular referenceto the issue of co-operation between a human operator and such anautomated device. The invention finds preferred application in the fieldof robotics, but can be implemented to advantage also on other devicesused in the industrial-production sector.

BACKGROUND

In order to exploit effectively the contribution of automation inproduction processes and thereby increase the efficiency of the latter,it is necessary to render interaction between human operators andautomated devices, in particular robots, natural and safe. In this way,human operators can be entrusted with those processes that would requirean excessively complex automation, whereas the operations that involve,for example, major effort, rapidity of execution, high precision, andquality can be entrusted to automated devices.

To render these production modalities possible, solutions are requiredthat render human interaction with the automated devices natural andsafe. The approaches currently adopted for this purpose are basicallylinked to the issues of passive safety and active safety.

With specific reference to industrial robots, the methodologies linkedto the increase of passive safety in the interaction between a humanoperator and the manipulator of a robot are basically aimed at modifyingthe structure and operation of the latter, in order to reduce thelikelihood of accidents and the degree of seriousness thereof. Accordingto this approach, robot manipulators have for example been proposed thatare distinguished by light structures, coated with soft materials andwithout sharp edges or corners in order to minimize the harm caused bypossible impact against a human operator.

The methodologies linked to the increase in active safety regard,instead, control strategies based upon a dedicated sensor system, aimedat guaranteeing a constant monitoring of the environment that surroundsthe manipulator of the robot, in order to modify in a dynamic way itsbehavior in the case of potentially risky situations, such as approachof a human operator to the manipulator or contact between the operatorand the manipulator during execution of a given function. The types ofsensors currently used for this purpose are basically the following:

-   -   sensors aimed at optical reconstruction of the geometry of the        environment surrounding the manipulator, such as video cameras        and laser scanners;    -   electrical sensors aimed at recognizing contact or collision        between the manipulator and a human operator, such as force        sensors or contact sensors;    -   electrical sensors aimed at recognizing the excessive approach        between the manipulator and a human operator, such as proximity        sensors.

Robots have been proposed in which the two strategies of passive safetyand active safety are integrated in a sensorized covering or coating ofthe corresponding manipulator. These coverings are in generalconstituted by a sort of “skin”, prevalently made of elasticallyyielding material, that embraces a corresponding part of the manipulatorand integrates contact sensors and/or proximity sensors.

Installation of these known coverings on the movable structure of themanipulator is in general complicated and far from practical. Also thecorresponding operation of removal or replacement of the covering or ofparts thereof in the case of occasional failures proves laborious.Similar problems are encountered also in automated devices with movableparts other than robots, used in the context of an industrialproduction.

SUMMARY

The present invention basically aims to provide a sensorized coveringfor an automated industrial device, in particular a robot, which isimmune from the aforesaid drawbacks, albeit ensuring a high degree ofco-operation between the device and a human operator, at the same timeensuring the necessary safety requirements.

This and further aims still, which will emerge clearly hereinafter, areachieved according to the present invention by a sensorized covering foran automated industrial device and by an industrial device having thecharacteristics specified in the attached claims.

The claims form an integral part of the technical teaching providedherein in relation to the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Further aims, characteristics and advantages of the present inventionwill emerge clearly from the ensuing description and from the annexeddrawings, which are provided purely by way of explanatory andnon-limiting example in which:

FIG. 1 is a partial and schematic perspective view of an automateddevice according to possible embodiments of the invention;

FIG. 2 is a schematic perspective view of a part of the device of FIG.1, with a sensorized covering according to possible embodiments of theinvention;

FIG. 3 is a partially exploded view of the part of the device of FIG. 2;

FIGS. 4 and 5 are schematic perspective views of two modules of asensorized covering that can be used in an automated device, accordingto possible embodiments, respectively in a separated condition and in acoupled condition;

FIG. 6 is a schematic cross-sectional representation of a possiblelayered configuration of a covering module of a sensorized coveringaccording to possible embodiments of the invention;

FIGS. 7-11 are partial and schematic illustrations of some alternateconfigurations of electrical connection between covering modules of asensorized covering according to possible embodiments of the invention;

FIG. 12 is a schematic perspective view of an alternate automated deviceaccording to possible embodiments;

FIG. 13 is a partially exploded schematic view of the device of FIG. 12,with a covering module omitted;

FIG. 14 is a schematic perspective view of an alternate automated deviceaccording to possible embodiments of the invention;

FIG. 15 is a schematic perspective view of the device of FIG. 14, with acovering module omitted; and

FIG. 16 is a schematic perspective view of an alternate automated deviceaccording to possible embodiments of the invention.

DETAILED DESCRIPTION

Reference to “an embodiment” or “one embodiment” in the framework of thepresent disclosure is intended to indicate that a particularconfiguration, structure, or characteristic described in relation to theembodiment is comprised in at least one embodiment. Hence,characteristics described with reference to “an embodiment”, “at leastone embodiment”, “one or more embodiments” and the like, that may bepresent in various parts in this description, do not necessarily allrefer to one and the same embodiment. Moreover, the particularconfigurations, structures, or characteristics may be combined in anyadequate way in one or more embodiments. The references used in whatfollows are provided only for convenience and do not define the sphereof protection or the scope of the embodiments.

It is moreover pointed out that, in the sequel of the presentdescription, the automated devices in relation to which possibleembodiments of the invention are exemplified will be described limitedlyto the elements useful for an understanding of the invention.

FIG. 1 is a schematic representation of an automated device for use inan industrial production, according to possible embodiments of theinvention. In the example illustrated, the device is a robot, whichcomprises a manipulator 1 with a number of degrees of freedom, having amovable structure 2 that includes a plurality of parts connectedtogether, as well as actuator means that can be controlled for causingdisplacements of these parts of the structure 2.

In the example illustrated, the robot is an anthropomorphic robot withsix degrees of freedom, having a stationary base 3 and a column 4rotatably mounted on the base 3 about a first axis A1 with verticalorientation. Designated by 5 is an arm mounted oscillating on the column4 about a second axis A2 with horizontal orientation. Designated by 6 isan elbow, mounted on the arm 5 for turning about a third axis A3, whichhas also a horizontal orientation, the elbow 6 supporting a forearm 7,which is designed to turn about its axis A4, which consequentlyconstitutes a fourth axis of movement of the manipulator 1. The forearm7 is equipped at its end with a wrist 8, mounted for movement accordingto two axes A5 and A6. The wrist 8 has a flange 9 for installation of anend effector (not represented). The end effector may be a device forpicking up a generic component, for example of the type illustrated inFIG. 12, or else a polishing or grinding device, for example of the typerepresented in FIG. 14. The aforesaid end effector may in any case be ofany type and have any function known in the field; for example, it maybe a welding torch or yoke, a paint-spray gun or a gun for applying asealant, a drilling spindle, etc.

The movable parts 4-8 are connected together by means of joints of aknown type, having associated thereto respective electric motors, someof which are designated by M, with corresponding geared motor-reducertransmission. In one or more embodiments, also the end effectorassociated to the flange 9 has respective actuator means, according to atechnique in itself known. Preferentially associated to the aforesaidjoints, or to the corresponding motors M, are corresponding transducers(not shown), for example of an encoder or resolver type, for positioncontrol.

The movements of the manipulator 1, i.e., operation of the motors of thejoints, are managed by a control unit 15 of the robot, which ispreferentially located in a remote position with respect to themanipulator 1 and is connected to the electrical/electronic parts of thelatter via the conductors of a wiring 16. The practical modes ofimplementation of the hardware and of software for the unit 15, which isprovided with a respective microprocessor control system, do not fallwithin the purposes of the present description, apart from some specificfunctions referred to hereinafter, which pertain to possible embodimentsof the invention.

In one or more embodiments, the control unit 15 is configured forcontrolling the manipulator 1 in a plurality of different operatingmodes, amongst which at least an automatic operating mode and preferablyalso a manual operating mode. For this purpose, the unit 15 comprisesselection means 17, which can be operated by a user for selection of adesired operating mode from the possible ones. In at least oneembodiment, the robot is able to operate at least in a Programming Mode,an Automatic Mode, and preferably a Remote Mode. In FIG. 1, thereference number 17 then designates a device for manual selection of thedesired operating mode from the possible ones. In the Programming Modean operator acts in the vicinity of the manipulator, for controllingoperation thereof, storing the program steps, and programming theoperating activities, for example by means of a portable programmingdevice (teach pendant) or a manual guide device associated to themovable structure of the manipulator 1, in particular at, or in thevicinity of, its end effector. Instead, in the Automatic Mode, the robotexecutes a pre-stored operating program of its own, possibly incombination with some other robots or automatic equipment, andco-operating with a human operator for the purposes of execution of aspecific task. Also in the Remote Mode, the robot executes an operatingprogram of its own inside a work cell, possibly co-operating with ahuman operator, but in this case start of execution of the program comesfrom a cell supervisor, such as a PLC, which, for example, controls boththe robot and other automated equipment present in the cell itself.

FIG. 1 is a schematic illustration of the manipulator 1 in a “naked”version thereof in order to clarify a possible conformation of itsmovable structure 4-8. However, in practical embodiments of theinvention, this movable structure is covered at least in part by asensorized covering (visible in FIGS. 2 and 3), where it is designatedas a whole by 20. In one or more embodiments, such as the onerepresented, the covering 20 covers at least in part also the stationarystructure of the manipulator 1, here represented by its base 3.

The covering 20 integrates sensor means, which may include contactsensor means, suitable for detecting contact or impact between themanipulator 1 and a foreign body, and/or proximity sensor means,suitable for detecting the presence of a foreign body within asubstantially pre-set distance from the manipulator, for examplecomprised between 0 and 15-20 cm. In various preferred embodiments, thecovering 20 integrates both the contact sensor means and the proximitysensor means. Given that, in its preferred applications, the robot is arobot of a collaborative type, the aforesaid foreign body is typicallyrepresented by a human operator, which operates in strict contact withthe manipulator 1.

The sensorized covering 20 comprises a plurality of covering modules,some of which are designated by the reference numbers 21 to 39 only inFIG. 2, which can be assembled together to form as a whole a sort ofbody that coats at least part of the movable structure of themanipulator 1, preferably but not necessarily practically the entiremovable structure 4-8 of the manipulator.

As will emerge more clearly hereinafter, at least some of the modules21-39 of the covering 20 have a respective load-bearing or supportingstructure, having a predefined shape, associated to which is at leastone layer of elastically yielding material, i.e., one designed to absorbimpact. In preferred embodiments, the load-bearing or supportingstructure of each module is made of rigid or semi-rigid material, sothat the structure can be provided with a desired predefined shape,which varies according to the part of the manipulator 1 (or otherautomated device) that is to be covered.

The plurality of modules 21-39 comprises one or more sensorized coveringmodules, which each include respective sensor means of the type referredto above. In the sequel of the present description, a possibleembodiment of the aforesaid sensorized modules will be exemplified withreference to the modules designated by 23 and 24, taking for grantedthat the concepts described in relation to these modules can be appliedalso to other sensorized modules, for example the ones designated by25-26, 28-29, 31-32, 36-37, 38-39 (obviously apart from the differentoverall shape of the modules in question, which is determined by thecorresponding load-bearing structure).

In preferred embodiments, the sensorized modules include both contactsensor means and proximity sensor means. On the other hand, not ruledout from the scope of the invention is the case of modules of thecovering 20 provided with just contact sensors or else just proximitysensors. The covering 20 may also include modules without sensors of thetype referred to, for example in areas of the manipulator 1 for whichthe risks or consequences deriving from possible impact with a humanoperator are reduced: for example, the covering modules 21-22 of thebase 3 of the manipulator 1 could be without sensors, or else beequipped with just proximity sensors, on account of the fact that thebase 3 is in any case a stationary part of the manipulator. Similarconsiderations may apply to modules associated to movable parts of themanipulator 1, for example the module 33.

In various embodiments, at least some of the modules of the covering areto be fixed in a separable way to corresponding underlying parts of themovable structure 4-8, such as the modules 23, 25 and 36, 37 of FIG. 2.For this purpose, the aforesaid underlying parts of the manipulator 1have purposely provided positioning and/or attachment elements forrespective covering modules. These elements may be defined directly bythe body of the parts of the manipulator, or else be configured aselements applied on these parts.

With reference, for example, to FIG. 1, designated by 18 a are, forinstance, two brackets for anchorage of the modules 23 and 25 of FIG. 2,designated by 18 b is a positioning and/or resting element for themodule 23, whilst designated by 18 c is a bracket for anchorage of themodule 34 of FIG. 2.

In various embodiments, fixing of the modules to the aforesaidpositioning and/or attachment elements is obtained by way of additionalmechanical-connection elements. For instance, partially visible in FIG.3, where the module 24 is separate from the modules 23 and 26, is anelement 19 for mechanical connection of the module 23 to the attachmentelement 18 a of the column 4 of the manipulator 1. On the other hand, inpossible embodiments, the load-bearing structure itself of the modulesthat is to be secured to parts of the manipulator 1—which is, forexample, made of mouldable or thermo-formable plastic material—may beshaped so as to define directly at least part of the elements necessaryfor mechanical connection and/or coupling to the structure 2 of themanipulator 1.

In one or more preferred embodiments, one or more first coveringmodules—for example the modules 23 and 25—are secured in a separable wayto respective parts of the movable structure (the column 4, withreference to the modules 23 and 25 exemplified), in particular viaquick-coupling means, for example members with snap-action orslotted-fit coupling elements.

In one or more embodiments, one or more second covering modules—forexample the modules 24 and 26—are secured in a separable way to one ormore of the aforesaid first modules and/or are secured in a separableway together, in particular by means of quick-coupling means, forexample members with snap-action or slotted-fit coupling elements. Forinstance, the modules 24 and 26 can be coupled in a separable way to themodules 23 and 25, respectively, which are in turn coupled in aseparable way to the structure of the manipulator. Moreover, as willemerge more clearly hereinafter, the modules 24 and 26 themselves arecoupled together in a separable way.

As has been said, preferentially, the means for separably coupling thecovering modules together and/or to the movable structure of themanipulator are quick-coupling means, such as releasable clips with snapaction or slotted-fit coupling elements. On the other hand, inalternative embodiments separable fixing of one or more modules to thestructure 2 and/or together could be obtained using threaded members,such as screws and the like.

In one or more preferred embodiments, modules of the covering 20 areprovided that have at least one electronic control board, preferablyassociated to the corresponding load-bearing structure. This controlboard is connected in signal communication with the control unit 15 ofthe manipulator 1, and electrically connected thereto are the sensormeans of at least one corresponding sensorized covering module.

This control board is preferentially prearranged for managing at leastoperation of the sensor means and for supplying to the control unit 15signals representing contact between the manipulator 1 and a humanoperator (or other foreign body) and/or signals representing thepresence of a human operator (or other foreign body) within asubstantially predetermined distance from the manipulator itself. As hasbeen said, in preferred embodiments, at least one of the sensorizedmodules includes contact sensor means and proximity sensor means so thatthe corresponding control board is able to supply to the control unit 15signals representing both of the aforesaid conditions, i.e., signalsrepresenting contact and signals representing proximity.

Each sensorized covering module may be provided with a control board ofits own, or else a sensorized covering module may be provided with anumber of control boards, for example a first board for management ofthe sensor means of the module in question and a second board formanagement of the sensor means of a different sensorized coveringmodule, which may hence be without a control board of its own. There mayalso be envisaged sensorized modules provided with a single board thatis able to manage both the sensor means of the aforesaid module and thesensor means of another module, which may hence be without a controlboard of its own. With the same logic, moreover, at least one controlboard can be carried by a non-sensorized module of the covering,connected to which are the sensor means of at least one sensorizedmodule, which may hence even be without a corresponding control board.It will thus be appreciated that one or more modules of the covering,even though they are provided with contact sensor means and/or proximitysensor means of their own, do not necessarily have to be equipped with acorresponding control board. In this perspective, the sensor means ofone or more sensorized modules without board may even be interfaceddirectly with the control unit 15, in which the functions of thecorresponding board will be directly implemented.

FIGS. 4 and 5 represent, by way of example, two sensorized coveringmodules, corresponding to the modules 23 and 24 of FIGS. 2-3. Visible inthese figures is the inner side of the aforesaid modules, i.e., the sidesubstantially facing the underlying movable structure of the manipulator1 (here basically the column 4, see FIG. 1).

Visible in these figures is the load-bearing or supporting structure ofthe modules in question, designated as a whole by 40. As will emergemore clearly hereinafter, in preferred embodiments, the modules of thecovering 20, have as a whole a layered structure, which includes:

at least one layer of rigid or semi-rigid material, necessary forbestowing upon the module a desired predefined shape;

at least one layer of yielding material, designed to absorb possibleimpact; and preferably

at least one outer coating layer.

In one or more embodiments, the sensorized modules comprise one or moreactive layers, corresponding to the sensor means provided, and one ormore passive layers, corresponding to the elastically yielding part ofthe module and to its outer coating. The load-bearing structure 40,which constitutes itself a layer of the covering module, is prearrangedfor supporting the aforesaid active and passive layers.

The structures 40 of the modules are substantially obtained in the formof shells shaped so as to follow the shape of the corresponding parts ofthe manipulator 1, i.e., to embrace it or cover it partially so as toprovide a substantially homogeneous surface for supporting the aforesaidactive and passive layers, as well as for the covering 20 as a whole.

The structures 40 are preferentially shaped so that between their innerside and the underlying parts of the manipulator 1 a free gap isdefined, sufficient for housing, for example, the control electronics ofthe covering modules, the corresponding wiring, and the possiblyprojecting elements of the aforesaid covered parts of the manipulator,as well as possible members for forced ventilation, for example fans. Ofcourse, for these reasons, the structures 40 of the various coveringmodules will be differentiated from one another, according to the areaof the manipulator that is to be coated. For this purpose, the structure40—which may indicatively have a thickness of between 2 and 5 mm,preferably 2.5-3.5 mm—is preferentially made of a thermoplastic polymer,for example ABS, and may hence be easily injection-moulded using knownequipment. However, not ruled out from the scope of the invention is theuse of thermosetting materials and/or formation of the structures 40 viathermoforming or other technologies in themselves known, for examplethree-dimensional printing.

In preferred embodiments, the structure 40 of at least some modules hasa shape and a thickness such as to enable collapse or shattering thereofin the case where the respective covering module is involved in animpact that occurs with kinetic energy higher than a substantiallypredefined safety threshold. This threshold is preferentially chosen soas to prevent serious risks to the safety of a human operator, in thecase of impact with the module in question: indicatively, the thresholdin question—representing a limit impact energy—may be comprised between100 N·m and 200 N·m, preferably approximately 150 N·m. In the case whereit is desired to ensure maximum protection, for example for preventingalso possible injury to the face of an operator, the safety thresholdmay be comprised between 60 N·m and 100 N·m.

With reference to FIGS. 4 and 5, it may be noted how, in one or morepreferential embodiments, the structures 40 are substantially shapedlike a shaped shell, preferably defining a more or less pronouncedcrowning or cavity, the inner side of which may be provided withstiffening ribbings, some of which are designated by 41. The controlboards of the modules, when envisaged, are fixed to the inner side of arespective structure 40: in the example represented, both of the modules23 and 24 are provided with respective control boards, designated by 50and represented schematically. Fixing of the boards 50 to the structures40 may occur according to known technique, for example via threadedmembers, or else gluing, or else by providing on the inner side of thestructures 40 corresponding brackets or seats for snap-action engagementof the boards 50.

Designated by 51 is the electrical wiring used for connection of theboards 50 to the sensor means of the respective module, which, in theexample considered, comprise contact sensors and proximity sensors.Given that these sensor means are positioned beyond the outer side ofthe structures 40 (not visible in FIGS. 4-5), the latter may be providedwith holes for passage of the wiring 51.

In various embodiments, the load-bearing structure 40 of at least someof the modules has associated to it mechanical connector means, formechanically connecting at least two covering modules together in aseparable way. In preferential embodiments, the aforesaid mechanicalconnector means are of the quick-coupling type, for example withsnap-action coupling elements.

As exemplified in FIG. 4, in preferred embodiments, the structure 40 ofa first module—in the example, the module 23—has at least one peripheralsurface or wall 42 designed to face a corresponding peripheral surfaceor wall 42 of a second adjacent module—in the example, the module24—where associated to said facing surfaces or walls are the aforesaidconnector means for mechanical connection, designated by 45 and 45′. Inthe example, the connector means 45 are substantially of a male type,whereas the connector means 45′ are substantially of a female type.Mechanical connectors of the type referred to may be provided also onmodules without sensor means.

In various embodiments, the load-bearing structure 40 of at least someof the modules has associated to it electrical connector means, forelectrically connecting together two covering modules, in a separableway. In the example illustrated in FIG. 4, the aforesaid electricalconnector means are designated by 46 and 47, the connector means 46being substantially of a male type and the connector means 47 beingsubstantially of a female type. Preferentially, and as exemplified inFIG. 4, the electrical connector means 46, 47 are associated to facingwalls 42 of two modules to be coupled electrically, here the modules 23and 24, preferably in addition, but possibly also as an alternative, tothe mechanical connector means 45, 45′.

It is clear that the structure 40 of a module—even without sensormeans—may have a number of surfaces or walls designed to facecorresponding surfaces or walls of adjacent modules, these facing wallshaving associated to them respective mechanical connector means and/orelectrical connector means: FIG. 4 represents, in fact, the case wherethe structure 40 of the module 24 has a surface or wall 43 (heregenerally transverse or orthogonal to the wall 42 of the module itself)that is provided with mechanical connector means 45, designed to couplewith respective complementary mechanical connector means provided on thesurface or wall of the module 26 designated by 43 in FIG. 3. In additionor as an alternative, on the walls 43 of the modules 23 and 26 therecould be provided electrical connector means of the type referred topreviously. There may obviously also be provided a number of electricalconnector means, on one and the same wall 42 or on a number of walls 42,43 of a first module, designed for separable coupling with complementaryelectrical connector means, carried by corresponding walls of secondmodules adjacent to the first modules.

Once again in FIG. 4, designated by 52 is the wiring for electricalconnection of the control board 50 of the module 24 to the correspondingelectrical connector means 46, whereas designated by 53 is the wiringfor connection of the electrical connector means 47 of the module 23 tothe control unit 15 of FIG. 1 (or else, as already mentioned, to anelectrical connector means 46 or 47 of another module, which is notnecessarily sensorized). Designated by 54 is the wiring for electricalconnection of the control board 50 of the module 23 to the control unit15 of FIG. 1 (or else to an electrical connector means 46 or 47 ofanother module, which is not necessarily sensorized). The supportingstructure 40 of the modules may be shaped so as to define, on aperipheral wall thereof, at least one passage for guiding the wiring, asillustrated, for example, for the module 23 in relation to the sets ofwiring 53, 54.

As emerges from FIG. 4, the shape substantially resembling a generallyconcave or crowned shell of the structures 40 ensures effective housingof the control boards 50 and corresponding sets of wiring 51-53, thelatter being preferentially anchored locally to the inner side of thestructures themselves, for example via adhesive tapes or suitablecable-runners.

In FIG. 5, the modules 23 and 24 are represented in a coupled condition,i.e., with the respective walls 42 of FIG. 4 in contact with or adjacentto one another, and with the mechanical connector means 45, 45′ and theelectrical connector means 46, 47 coupled together. With reference tothis drawing, it is assumed that the ends of the sets of wiring 53 and54 are electrically connected to the control unit 15 of FIG. 1, withsome conductors of the wiring that are used by the control unit 15 forproviding the necessary electric-power supply (preferably a low-voltagesupply) to the control boards 50, and other conductors of the aforesaidwiring that are, instead, used by the control boards 50 for supplying tothe control unit 15 the signals representing detections made by thesensor means, i.e., detection of a contact or impact between themanipulator 1 and a human operator (or other foreign body) and/or thepresence of a human operator (or other foreign body) in the proximity ofthe manipulator itself.

In this way, thanks to the independent electrical connections, variousmodules of the covering 20—here exemplified by the modules 23 and 24—areable to operate independently of one another, even in the event offailure of one of the modules. An approach of this sort evidentlyenables various possible configurations for the covering 20, which maycomprise sensorized modules that substantially cover the entire movablestructure of the manipulator 1 or else just a part thereof deemedcritical for the purposes of co-operation with a human operator,according to final application of the robot.

It will likewise be appreciated that, in this way, the control unit 15may also be prearranged for identifying the control board 50 of thesensorized module that supplies one of the aforesaid signalsrepresenting contact or proximity, with the control unit itself thathence recognises the module in question, corresponding to the area ofthe manipulator in which there has occurred contact and/or there hasbeen detected proximity of an operator or other foreign body, in orderto undertake the necessary actions.

For instance, given that the proximity sensor means are configured fordetecting the presence of a foreign body within a maximum distance of15-20 cm, following upon a detection made via said sensor means, thecontrol unit can govern a reduction of the speed of displacement of themanipulator 1 to a speed deemed safe for a human operator, for examplecomprised between 150 and 250 mm/s.

Similar strategies may be implemented following upon contact caused by ahuman operator against the manipulator. For instance, suppose that,after a reduction of speed caused by a previous signal generated by theproximity sensor means, the human operator performs an unexpecteddisplacement and accidentally bumps against the surface of a sensorizedmodule. Following upon the consequent signal generated by the contactsensor means, the control unit 15 may stop the movement of themanipulator 1, or else reverse the direction movement thereof. It shouldbe noted that the contact made by the operator against the sensorizedcovering may also be voluntary, for example when the operator himselfwants to stop operation of the robot.

The fact that the control unit 15 is able to identify the sensorizedmodule from which the contact and/or proximity signals come willpossibly enable adoption of control strategies aimed at increasing thesafety of a human operator, in particular for coordinating the movementof a number of parts of the movable structure 2. With reference forexample to FIG. 2, suppose, for example, that a contact is detected viathe module 39, when the forearm (7, FIG. 1) of the manipulator 1 islocated in a position inclined downwards. A possible control strategymay then envisage that the control unit 15 will drive both a raising ofthe aforesaid forearm 7 and a simultaneous oscillation backwards (asviewed in FIG. 1) of the arm 5. Obviously, this is only a non-limitingexample, given that the possible combinations of movements areinnumerable.

It will be appreciated that, in one or more embodiments, the controlunit 15 may be configured, via suitable programming, for exploiting thesensorized covering modules as a sort of user interface, aimed atenabling the human operator to impart basic instructions on the controlunit 15.

As already mentioned, a single contact with a sensorized module may bedeemed indicative of a situation that is potentially dangerous for ahuman operator, following upon which safety strategies are implemented.On the other hand, for example, three contacts on a sensorized modulethat occur in rapid succession (that the operator may make even withjust the finger of one hand) may indicate the desire on the part of theoperator to stop the manipulator temporarily, without the robot havingto implement any safety strategy. Starting from this condition ofcontrolled arrest, a subsequent sequence of contacts on a module—forexample two or four contacts in rapid succession—may indicate theintention of the operator to restart operation of the manipulator.

In various embodiments, adjacent modules of the sensorized covering 20are not provided with mechanical connector means and electricalconnector means of the type referred to previously. This is typicallythe case of modules that, albeit rather close to one another, coverparts of the manipulator 1 capable of relative movement.

With reference to FIG. 2, it will be appreciated, for example, that themodule 23, on the one hand, and the module 28 (or 29), on the other,partially cover the column 4 and the arm 5 of the manipulator 1 (seeFIG. 1), respectively, i.e., parts of the manipulator that are able toperform relative displacements. Between these modules 23 and 28 nomutual-coupling connector means, whether mechanical or electrical, arehence provided. If necessary, electrical connection may be obtainedusing flexible cables that extend between the modules in question,exploiting the already mentioned free housing spaces allowed by theshell-like shape of the structures 40 of the modules themselves; thesespaces are also sufficiently wide to enable movements of the aforesaidcables as a result of displacements of the movable parts 4 and 5. Ofcourse, considerations of this type also apply to other modules of thesensorized covering 20, such as—with reference once again to FIG. 2—themodules 23 or 25 and 29, the modules 29 and 30, the modules 38-39, onthe one hand, and the modules 36-37, on the other, or again the modules30, 31, 34, 35, on the one hand, and the modules 36-37 on the other (themodules 36-37 are fixed with respect to the forearm 7 and are thus ableto turn therewith with respect to the modules 30, 31, 34, 35 that coverthe elbow 6 of FIG. 1).

As mentioned previously, in preferential embodiments, at least thesensorized modules of the covering 20 comprise a plurality of activelayers and passive layers supported by the load-bearing structure 40.

Represented in FIG. 6 merely by way of non-limiting explanation is apossible layered structure of a sensorized module, which is here assumedas being the module 24 of FIGS. 4 and 5. In this figure, representationof the electrical-connection wiring has been omitted for reasons ofgreater clarity.

In preferred embodiments, associated to an outer side of the supportingstructure 40 of a covering module is a cushioning layer, made ofelastically yielding material, which is prearranged for absorbing thekinetic energy deriving from impact against the module in question. Thiscushioning layer, designated by 60 in the example of FIG. 6, may be madeof a polymeric foam, for example expanded polyurethane. The layer 60 mayhave a thickness of between 5 and 10 mm, preferably approximately 6-8mm.

Preferentially, the cushioning layer 60 is prearranged for absorbing akinetic energy not higher than the safety threshold referred topreviously, corresponding to collapse or failure of the load-bearingstructure 40. Indicatively, then, and with reference to what haspreviously been exemplified in relation to the structure 40, thecushioning layer 60 may for example be prearranged for absorbing impactwith a kinetic energy lower than 60 N⋅m, or else 100 N⋅m, or else 150N⋅m, or else 200 N⋅m, according to the desired degree of safety.

In one or more embodiments, provided on top of the cushioning layer 60of a sensorized module are the contact sensor means. In general, thecontact sensor means may be of any known type.

In preferred embodiments of the invention, the contact sensor means areof a flexible type and provided so as to extend over an areasubstantially corresponding to that of the outer face of the module inquestion, or to a prevalent part thereof. In the non-limiting example ofFIG. 6, these contact sensor means are designated as a whole by C andhave themselves a structure formed by layers set on top of one another.

In one or more embodiments, the contact sensor means comprise apiezoresistive layer 62, which is set between a lower electricallyconductive layer 61 and an upper electrically conductive layer 63.Preferentially, the piezoresistive layer 62 comprises a fabric made ofpiezoresistive material or a material rendered piezoresistive, forexample a fabric made of synthetic insulating material (such as nylonand/or spandex) coated with a conductive polymer. Piezoelectric fabricsof this type are, for example, manufactured by Eeonyx Corporation,U.S.A. The layers 61 and 63 preferentially comprise a fabric made ofelectrically conductive material or material rendered electricallyconductive such as, for example, a metal fabric. Conductive fabrics ofthis type are, for example, manufactured by Texe S.r.l., Italy, bearingthe trademark INNTEX.

The layers or fabrics 61-63 are very thin (indicatively, the overallthickness of the layers 61-63 set on top of one another does not exceed5 mm, preferably 2.5-3.5 mm) and are hence intrinsically flexible.

In operation, a difference of potential is applied between theconductive layers 61 and 63, and the electrical resistance of thepiezoresistive layer 62 is measured via corresponding componentsprovided on the corresponding control board 50. In the presence of apressure applied on the layers 61-63, the local resistance of thepiezoresistive layer varies, for example decreasing, it being thenpossible to detect this variation via the aforesaid components of theboard 50.

The contact between the two conductive layers 61, 63 is a particularcondition that corresponds to a resistance of the intermediatepiezoelectric layer of 0Ω, such as to produce a false response of thesensor C. For this reason, in various embodiments, the piezoresistivelayer 62 has perimetral dimensions larger than those of the conductivelayers 61 and 63, in such a way that a peripheral portion of the layer62 projects peripherally beyond the layers 61 and 62. This configurationhence creates the presence of a sort of non-sensitive frame, whichsurrounds the sensitive part of the sensor: the presence of theprojecting peripheral part of the layer 62 prevents direct contactbetween the layers 61, 62, and hence prevents short circuits that wouldgive rise to false responses.

In preferential embodiments, the contact sensor means of a sensorizedcovering module are set between a lower covering layer and an uppercovering layer, which are made of elastically yielding and electricallyinsulating material. With reference to the non-limiting example of FIG.6, designated by 64 and 65 are the aforementioned lower and uppercovering layers, respectively, set between which are the contact sensormeans C. The layers 64 and 65 may be made of a polymeric foam,preferably a closed-cell polymeric foam. Preferentially, the layers 64and 65 have a thickness of less than 4 mm, preferably 1.5-2.5 mm.

When a charge is applied on the upper covering 65, for example followingupon impact between the covering module in question and a humanoperator, the yielding material of the layers 64 and 65 undergoesdeformation, thus determining a pressure on the active layers 61-63, andthereby activating the contact sensor means C, as explained above. Theinternal structure of the polymeric foam used for the production of thelayers 64 and 65 hence enables transmission of the forces practicallycompletely to the sensor means C set in between, absorbing only a modestamount of energy.

As may be noted, in the example of FIG. 6 the lower covering layer 64 isset on top of the cushioning layer 60.

The sensitivity of the sensor means C depends of course upon variousaspects and properties of the layers 61-63 chosen and of thecorresponding covering layers 64-65 (such as the electrical resistanceof the piezoelectric layer or fabric 62, the elasticity of the layer orfabric 62 and of the layers or fabrics 61, 62, the type of material ofthe covering layers 64, 65, its density and compressibility, thethickness of the covering layers 64, 65, and the position of the sensormeans C within the layered structure of the covering module). For thispurpose, the desired calibration for the sensor means C may be performedin the design stage and on the basis of experimental tests, according tothe type of implementation chosen (shapes, materials, thicknesses, etc).

It should be considered that the contact sensor means C of the typereferred to are also suitable for performing functions of force sensors,considering that the greater the pressure exerted thereon (i.e., on theoutside of the covering module), the more the value of resistancedetected differs (e.g., is lower). On this basis, the control unit 15may be prearranged to interpret a strong and prolonged thrust for someseconds (e.g., 2-3 seconds) as a command aimed at obtaining movement ofthe manipulator in a direction opposite to the one from which the thrustcomes. In this way, an operator can exert with his hand such a thrust ona given sensorized covering module, in order to bring about displacementof the manipulator in the opposite direction, as long as the thrust ismaintained.

As has been said, in one or more embodiments, one or more sensorizedmodules comprise proximity sensor means. When a sensorized modulecomprises both the contact sensor means and the proximity sensor means,the latter are in a higher position than the former, i.e., in a moreexternal position with respect to the structure 40, which represents theinnermost layer of a covering module. In the case of sensorized modulesthat include, instead, only the proximity sensor means, the layers61-64, and possibly 65, of FIG. 6 may be omitted, possibly increasingthe thickness of the cushioning layer 60 accordingly.

The proximity sensor means may be of any known type, but are alsopreferably of a flexible type and obtained so as to have a surface areasubstantially corresponding to that of the outer face of the module inquestion or of a predominant part thereof. In the non-limiting exampleof FIG. 6, these proximity sensor means are designated as a whole by Pand have themselves a structure consisting of layers set on top of oneanother.

In one or more embodiments, the proximity sensor means are of acapacitive type and comprise a first layer and a second layer ofelectrically conductive material, set between which is at least onelayer of electrically insulating material. With reference to thenon-limiting example of FIG. 6, designated by 66 and 68 are theaforesaid first and second conductive layers, whereas designated by 67is the aforesaid intermediate insulating layer, the upper layer 68 beingthe sensitive layer for the purposes of proximity detection.

Preferentially, the conductive layers 66 and 68 each comprise a fabricmade of electrically conductive material or a material renderedelectrically conductive, for example a polyester fabric plated withcopper and coated with nickel. Conductive fabrics of this type aremanufactured, for example, by 3M Company, U.S.A. In various embodiments,the intermediate layer 67 is preferably made of elastically yieldingmaterial, for example a polymeric foam, preferably a closed-cellpolymeric foam.

As may be noted, in the example of FIG. 6, the first electricallyconductive layer 66 is set on top of the upper covering layer 65.

In a possible practical embodiment, the proximity sensor means Pcomprise the conductive layer 68, used as capacitive sensor, which isconnected to a capacitive sensing chip based upon an LC circuit (such asthe chip FDC2214 manufactured by Texas Instrument Incorporated, U.S.A.),provided on the control board 50 for acquisition and processing of thedata (see the data sheet of the chip referred to above and thecorresponding application notes). Basically, when a human operator (orother foreign body) approaches the conductive layer 68 there occurs avariation of capacitance in the LC module and a consequent variation ofan oscillating frequency. The measurement of this frequency variation,made by the chip, hence represents the proximity of the human operator(or other foreign body) to the layer 68, i.e., to the outer side of thesensorized covering. As already mentioned, the sensor means P may beconfigured in such a way that the maximum distance from the layer 68within which the presence of a foreign body can be detected isapproximately 15-20 cm.

The conductive layer 66, set underneath the sensitive layer 68, operatessubstantially as a screen, in order to prevent false detections, due forexample to movements of objects that are located beyond the inner sideof the load-bearing structure 40 (consider a wiring that displacesfollowing upon a movement of the manipulator), which would reduce thesensitivity of the layer 68 with respect to the opposite side of thecovering module that is of actual interest. The lower conductive layer66 may be used as a passive screen or as an active screen, according tothe type of connection implemented on the board 50. As has been said,the sensitive layer 68 and the screen layer 66 of the sensing means Pare separated from one another by the layer 67.

Finally, each module preferentially comprises an outer coating layer,which may for example be made of a technical fabric or of a syntheticleather. With reference to the non-limiting example of FIG. 6, thecoating layer is designated by 69. The layer 69 has in particular thefunction of insulating the sensor means P from the outside of thecovering module, preventing direct contact of the conductive layer 68with persons or objects.

In the case of sensorized modules in which the coating layer 69 is seton top of the second electrically conductive layer 68 of the proximitysensor means P, it is then preferable for the aforesaid coating layer 69to be made of electrically insulating material. In the case ofsensorized modules that include just the contact sensor means C, thecoating layer 69 will, instead, be set on top of the upper coveringlayer 65, which is in itself already electrically insulating, or else,in the absence of the latter, on the conductive layer 63. The coatinglayer 69 may have a thickness comprised between 0.5 and 1.5 mm, eventhough a larger thickness thereof is not ruled out, provided that aflexibility or elastic yielding thereof is guaranteed.

In various embodiments, such as the one exemplified in FIG. 6, thecoating layer 69 extends also on the peripheral sides of the structureconstituted by the layers 40, 60-68 and is secured to the load-bearingstructure 40, for example to its inner side and/or to walls of the typedesignated by 42-43 in FIGS. 4-5. This does not, however, constitute anessential characteristic. The coating layer 69 may in fact be formed bya suitable paint, preferably an electrically non-conductive paint.

Also represented schematically in FIG. 6 are the control board 50 of themodule 24 exemplified, as well as means for forced ventilation,designated by 70, for example a fan with electric motor.

In various embodiments, one or more fans 70 may be mounted on parts ofthe structure of the manipulator 1 covered by the covering 20, wherethese parts are provided with suitable supports designed for thepurpose. On the other hand, according to preferred embodiments, the fansare mounted on the inside of the structure 40 of one or more modules,which are not necessarily sensorized modules. The presence of thesemeans of forced ventilation favors circulation of air within the cavitydefined by the covering 20, for example in order to facilitate coolingof components enclosed within the covering (such as the boards 50 or themotors M of the joints of the manipulator 1). In order to enablecirculation of the cooling air (i.e., intake of air from outside andexpulsion of the hotter air outwards), one or more modules of thecovering 20 may be provided with passages, for example in the form of aseries of slits, represented schematically dashed in FIG. 2.

Operation of the ventilation means 70 may be controlled by the controlboard 50 of a sensorized module (not necessarily the same as that onwhich the fan is mounted). For this purpose, in possible embodimentssuch a board 50 is advantageously provided with a temperature sensor(e.g., of an NTC type) in order to activate the ventilation means whenthe temperature of the air detected within an area circumscribed by thecovering 20 reaches or exceeds a predefined threshold.

In various embodiments, for the purposes of production of a sensorizedmodule, such as the module 24 of FIG. 6, the various layers areassembled using adhesives, which are designed to keep the layersadherent to one another and prevent any possible sliding thereoffollowing upon contact or impact.

As already mentioned, the base layer represented by the load-bearingstructure 40 is obtained in the form determined in the design stage, theshape of which will be variable according to the area of the manipulatorto be covered. The structure 40 is preferentially made of a rigid orsemi-rigid plastic material, via injection moulding, or thermoforming,or other suitable technique.

Next, the cushioning layer 60 is set on the corresponding load-bearingstructure 40 and fixed thereto via adhesive. For this purpose, the layer60 is obtained with a shape and size such as to reproduce at least thoseof the outer side of the load-bearing structure 40 in order to cover itentirely or practically entirely. The layer 60 may, for example, be cutor dinked from a sheet of the material used. Also the active layers61-63 and the covering layers 64 and 65 are obtained in the necessaryshapes and sizes, for example via cutting or clinking (as has been said,preferentially the piezoresistive layer 62 has a greater width than theconductive layers 61, 63), and gluing thereof is then carried out. Thecovering layer 64 is glued on the cushioning layer 60 and the layers61-63 are then glued thereon in succession, the covering layer 65 beingthen glued on the layer 63. The layers 61-65 are assembled together, inthe order illustrated, preferably using one or more glues having areduced adhesive capacity or in any case an adhesive capacity less thanthat of the glue or glues used for securing the layer 60 to thestructure 40, the aim being not to alter the elasticity of the sensitivelayers 61-63, but at the same time to obtain a stable sensor. Of course,application of the glues between the layers 61-63 is such as not toinsulate said layers electrically from one another.

Next, also the further active layers 66, 68 and the correspondingintermediate passive layer 67 are obtained in the necessary shapes andsizes in order to cover an area substantially corresponding to the outerface of the covering module or to a prevalent part thereof. As for theprevious layers, also in this case it is possible to use techniques ofcutting or clinking starting from larger sheets of the startingmaterials.

The layers 66-68 are then glued in succession on the layer 65, also inthis case preferably using glues with reduced characteristics ofadhesion, for the reasons explained above in relation to the layers61-65.

Finally, the outer coating layer 69 is applied, which may also be gluedon the underlying layered structure or else, as mentioned, applied inthe form of paint.

FIG. 7 is a schematic illustration of a possible mode of connection ofsome sensorized modules, such as for example the modules 23-24 of FIGS.4-5 and the modules 28-29 of FIG. 2. As already mentioned, inembodiments of this type, sets of wiring 53, 54 are provided thatconnect the control boards 50 of the various modules to the control unit15, where these sets of wiring include conductors for carrying theelectric-power supply from the unit 15 to the boards 50 and for carryingfrom the boards 50 to the unit 15 the signals representing detectionsmade by the sensor means C and/or P, the wiring 53 exploiting thepresence of the wiring 52 and of the electrical connector means 46-47 ofthe coupled modules.

Of course, the configurations of electrical connection of the coveringmodules to the control unit 15 may be multiple according to the designapproach adopted. For instance, FIG. 8 is a schematic illustration ofthe case already referred to of modules—here exemplified by the modules23 and 28—associated to the load-bearing structures of which are twocontrol boards 50, one in signal communication with the sensor means Cand/or P of the corresponding module 23 or 28, and the other to whichsets of wiring 51′ are connected for connection to the sensor means Cand/or P of the adjacent modules 24 and 29, respectively. In this case,the electrical connector means 46-47 are exploited for connectingtogether the sets of wiring 51′ provided on the modules 23 and 28 to thesets of wiring 51 provided on the modules 24 and 29.

FIG. 9 exemplifies, instead, the case of boards 50′ prearranged forconnection to a plurality of sensor means C and/or sensor means P. Inthe example, the boards 50′ are associated to the load-bearingstructures of the modules 23 and 28 and connected both to the respectivesensors C and/or P via the sets of wiring 51 and to the sensors C and/orP of the modules 24 and 29, via the sets of wiring 51′ on the modules 23and 28 and the sets of wiring 51 on the modules 24 and 29. Also in thiscase, the electrical connector means 46-47 of the adjacent modules 23-24and 28-29 are exploited for connecting together the sets of wiring 51′and the sets of wiring 51 of the modules coupled together. In solutionsof this type, sets of wiring 54′ are then provided that extend onlybetween the unit 15 and the modules 23, 28 (i.e., the correspondingboards 50′) for electrical supply and for carrying the signals generatedvia the sensor means C and/or P of all the modules represented.

FIG. 10 exemplifies the case of a connection in series between theboards 50 of various sensorized modules and the control unit 15,substantially according to an architecture of a daisy-chain type. Inthis case, a wiring 55 is substantially provided, which comprisesconductors for carrying electric-power supply to the boards 50 of thevarious modules 23, 24, 28, 28, and conductors for carrying the datarepresenting the detections made via the sensors C and/or P of thevarious modules connected. The boards 50 may conveniently includerespective communication nodes for transmission of the aforesaid data,according to a suitable standard or proprietary protocol.

In the case exemplified, the wiring 55 is divided into lengths, some ofwhich are present on the various modules, between each board and arespective electrical connector means 46 or 47, as well as secondlengths for connecting together non-adjacent modules or in any casemodules not provided with mutual-coupling connector means (such as themodules 24 and 28). These second lengths may be conveniently equipped,at the ends thereof, with electrical connector means 46′, 47′complementary to the electrical connector means 46 and 47 of the modulesto be connected. It will thus be appreciated that, in one or moreembodiments, the modules may be provided also with a plurality ofelectrical connector means 46, 47.

FIG. 10 likewise illustrates the case of modules—such as the moduledesignated by 21—which, albeit not provided with sensors C and/or P, arein any case equipped with electrical connector means.

It will be appreciated that, in various embodiments, the configurationof the network used for connecting together the control unit 15 and aplurality of modules may be different from the one exemplified in FIG.10, for instance using a bus architecture, a ring architecture, a stararchitecture, etc.

It should be noted that, in embodiments with a connection in series ofthe type exemplified in FIG. 10, removal of a module that determinesseparation between two connector means 46-47 causes interruption of thesensor functions of the entire covering 20. This may be convenient insome applications for reasons of safety. In other applications, theremay, instead, be used other connection architectures, for example a busarchitecture or else a star architecture (substantially as in FIGS.7-9), in order to guarantee operation of the covering also in the caseof removal of one or more modules provided with electrical connectormeans.

Exemplified in FIG. 11 is a case similar to that of FIG. 10, i.e., ofcontrol boards 50′ configured for managing the signals of the sensormeans C and/or P corresponding to a number of modules that are differentbut are interconnected via the electrical connector means 46 and 47.These boards 50′ are additionally equipped with a wireless communicationmodule, designated by W1, for transmission in radiofrequency at least ofthe signals corresponding to the detections made by the sensor meansconnected. For this purpose, the control unit 15 is equipped with acorresponding wireless communication module W2.

For the purposes of wireless data transmission the standard ofcommunication deemed most convenient for the application (WiFi,Bluetooth, ZigBee, etc.) may be used. Likewise, data transmission maytake place according to a suitable standard or proprietary protocol. Thesets of wiring 56 between the control unit 15 and the modules 23, 28will be used for electrical supply of the control boards 50′ with theassociated communication modules W1, which may, if necessary, also be ofa type that is able to manage a bi-directional communication.

Obviously, implementation of wireless data communication may be appliedalso to the cases exemplified in FIGS. 7 and 8, in which case the setsof wiring 53 and 54 may include only conductors for electrical supply ofthe boards 50.

The concepts previously set forth above as regards construction,operation, and connection of modules of a sensorized covering areapplicable to automated devices having one or more movable parts thatmay even be different from a manipulator of an industrial robot.

For instance, a sensorized covering of the type described above—albeitobtained with modules having shapes different from the ones representedin FIGS. 2-5—may advantageously be used for partial covering of robottools or end effectors. Such a case is exemplified in FIG. 12, wheredesignated as a whole by 100 is a gripper tool, the load-bearingstructure 101 of which includes an attachment part prearranged—accordingto techniques in themselves known—for mechanical connection and possiblypower connection (of an electrical, pneumatic, or hydraulic type) to theflange 9 of the manipulator 1 of FIGS. 1-3. Associated to the structure101 are suitable actuator means, such as one or more pneumatic cylinders102 that can be controlled for bringing about opening and closing ofmembers or jaws—one of which is visible in FIG. 13 and designated by103—for picking up a workpiece to be machined or handled.

As may be noted, in the schematic example illustrated, associated to thestructure 101 are a plurality of covering modules 110, 111 and 112, 113,which provide two sensorized coverings 120 for different areas of thetool 100. In particular, the modules 110 and 111 are designed tosurround an upper portion of the tool 100, closer to the portion forattachment to the flange of the manipulator, whereas the modules 112 and113 are designed to surround a lower portion of the tool 100, movablewithin which are the aforesaid pick-up members 103.

In FIG. 13, the representation of the module 111 has been omitted,whilst the module 113 is represented in a condition separate from themodule 112. The modules 110-111 and 112-113 are provided with therespective electrical connector means, which may be coupled together inthe assembled condition of the two modules in question, there beingpartially visible in FIG. 13 only the connectors 46 and 47 of themodules 112-113. These electrical connector means may be configured alsoto fulfil the function of mechanical connection between the two modules(and this may apply, in principle, also to at least some of the modulesdescribed with reference to FIGS. 1-5). In any case, in embodiments ofthe type exemplified in FIGS. 13 and 14, the modules 110-111 and 112-113may be provided with respective releasable mechanical connector means,in particular quick-coupling means, of any known conception and suitablefor the given application.

In various embodiments, a robot tool or other end effector, thestructure of which is covered at least in part by a sensorized coveringof the type described herein, is provided for use in strict co-operationwith a human operator and includes for this purpose a manual-guidedevice.

For instance, FIGS. 12 and 13 exemplify an embodiment in which such aguide device includes a plurality of grips 115, on each of which theoperator can exert a force (thrust, pull, raising, lowering) in acertain direction to get the manipulator 1 to perform correspondingmovements necessary for execution of the process. Associated to thegrips 115 is a force sensor, which is connected in signal communicationto the control unit 15 (in wired or wireless mode) in order to enablethe latter to recognize the direction of displacement desired by theoperator. Preferentially associated to each grip 115 is a correspondingpush-button for control of switching of the pick-up elements 103 betweenthe respective opening and closing positions.

In the case exemplified, four grips 115 are provided at four differentsides of the tool 100 in order to enable the human operator to chooseeach time the grip deemed most convenient for carrying out an operationto be executed in co-operation with the robot.

Exemplified in FIGS. 14 and 15 is a different tool or end effector,designated as a whole by 200, in particular a grinding or polishingtool. Also in this case, the load-bearing structure 201 of the tool 200includes an attachment part prearranged for connection to the flange 9of the manipulator 1 of FIGS. 1-3. Associated to the structure 201 aresuitable actuator means, such as an electric motor 202 that can becontrolled for bringing about rotation of a disk 203 for abrading orpolishing a workpiece being machined.

In the schematic example illustrated in FIG. 14, associated to thestructure 201 are two covering modules 210, 211 aimed at providing asensorized covering 220 that prevalently surrounds the structure 201,leaving the machining disk 203 exposed. In FIG. 15—where representationof the module 210 has been omitted—it may be appreciated how, also inthis case, the modules 210-211 are provided with the respectiveelectrical connector means (here only the connector 47 associated to theload-bearing structure of the module 211 is visible), which may becoupled together in the assembled condition of the two modules inquestion. For the rest, there apply the considerations already set forthin relation to the tool 100 of FIGS. 12-13.

In the case exemplified, also the tool 200 is provided with amanual-guide device, which here includes two generally parallel handles115 associated to a force sensor in signal communication with thecontrol unit of the robot in order to enable the operator to bring aboutdisplacements of the manipulator, and hence of the tool 200, in thedesired working direction. Also in this case, the grips or handles 215each have a corresponding push-button for control of rotation of themotor 102.

The sensorized covering according to the invention may also be appliedto devices for movement of components being processed. An example inthis sense is illustrated schematically in FIG. 16, where designated asa whole by 300 is a vehicle with automatic drive, for example of thetype known as AGV (Automated Guided Vehicle), for transport of a genericworkpiece K in a production framework. Associated to the load-bearingstructure 301 of the vehicle 300 are wheels 302, some of which aredriven in rotation via a suitable motor, preferably an electric motor(not visible). The structure 301 moreover supports a control system 303of the vehicle, for example comprising a control unit and a userinterface for setting operating parameters, according to techniques inthemselves known. In conformance with the invention, the structure 301is equipped with a sensorized covering, designated as a whole by 320,electrically connected to the aforesaid control unit. Provided in theexample is a plurality of covering modules 321-328, preferably but notnecessarily all sensorized, shaped so that, in their assembledcondition, they surround the structure 301 substantially completely.Preferentially, the top of the structure 301 is, instead, kept exposed,in order to support thereon the workpiece K being carried. Also in thistype of implementations, there apply the principles previouslydescribed, and hence, for example, provision in at least some of themodules 321-328 of contact sensor means and/or proximity sensor means,and of electrical connector means and possibly mechanical connectormeans, for electrical and possibly mechanical interconnection,respectively, of a number of adjacent modules, and so forth.

The modules illustrated with reference to FIGS. 12-16 may be obtainedlike the modules described with reference to the previous FIGS. 1-11.

The invention can of course be applied also to other types of automateddevices used in industrial production and distinguished by the presenceof one or more parts subject to movement in areas potentially close to ahuman operator, such as rotary tables and slides.

From the foregoing description the characteristics of the presentinvention emerge clearly, as likewise do the advantages that it affords.

The modular nature of the sensorized covering described, with thepossibility of electrical interconnection and preferably also mechanicalinterconnection between the various modules, enables multipleconfigurations to be obtained, with the possibility of sensorizingsubstantially the entire movable structure of an automated device orelse only a part thereof, according to the type of application.

The solution enables convenient installation of the covering modules,and their equally convenient removal in the case of need. To this is tobe added the advantage that, in various embodiments, the modalities ofelectrical interconnection between the various modules enable operationthereof independently of one another.

The presence of a load-bearing structure enables definition of the shapeof the individual modules according to the application, with thepossibility of providing sensorized coverings for various types ofautomated devices. The shell-like nature of the load-bearing structuresof the modules enables definition of useful spaces, which can houseelectrical/electronic parts of the covering system and of parts of theautomated device and can moreover be exploited for ventilation purposes.

The presence of the sensor means integrated in at least some of themodules of the covering enables detection of contact of foreign bodieswith, or approach thereof to, the covering itself, as well asidentification of the area of the covering involved in the contact withthe foreign body or in the approach of the latter, with the possibilityof undertaking consequent corrective action. The sensor means, inparticular the contact sensor means, may be exploited to advantage forsupplying commands to the control system that supervises operation ofthe automated device.

Also the passive safety functions are ensured thanks to the presence ofelastically yielding layers, which are thus able to absorb impact, aswell as by the capacity of collapse of the load-bearing structures ofthe modules in the case of significant impact.

It is clear that, numerous variations may be made by a person skilled inthe art to the sensorized covering and to the automated device describedby way of example, without thereby departing from the scope of theinvention as defined by the ensuing claims.

The invention may be applied on industrial robots of different size andloads and hence both robots for modest loads (e.g., just a fewkilograms) and robots for high loads (e.g., hundreds of kilograms), aswell as on robots of a type different from the anthropomorphic onesexemplified herein, for instance robots having a cartesianconfiguration, a cylindrical configuration, a polar configuration, aSCARA (Selective Compliance Assembly Robot Arm) configuration, etc.

The various passive layers referred to previously, for example thecushioning layer 60, may in turn be constituted by a number of layers ofmaterial set on top of one another and rendered fixed with respect toone another, for example via gluing.

What is claimed is:
 1. An automated device comprising: a movablestructure; an actuator for causing displacements of the movablestructure; a control system including a control unit and operable tocontrol the actuator; a sensorized covering for covering at least partof the movable structure, wherein the sensorized covering comprises atleast one of a contact sensor or a proximity sensor, wherein thesensorized covering further comprises a plurality of covering modulesmutually couplable in a separable way, each covering module of theplurality of covering modules including a respective load-bearingstructure having a predefined shape to which at least one layer ofelastically yielding material is connected, wherein at least two of saidplurality of covering modules each having connected thereto at least oneof: an electrical connector operable to electrically interconnect in aseparable way the at least two covering modules to each other, or amechanical connector operable to mechanically interconnect in aseparable way the at least two covering modules positioned adjacent toeach other.
 2. The automated device of claim 1 wherein the automateddevice is a robot.
 3. The automated device according to claim 1, whereinsaid at least one of an electrical connector or a mechanical connectoris connected to the load-bearing structure of the at least two coveringmodules.
 4. The automated device according to claim 3, wherein the atleast two covering modules further comprise a first covering modulehaving at least one surface or wall facing a surface or wall of anadjacent second covering module, to said surface or wall of the firstcovering module there being connected at least one of a first electricalconnector or a first mechanical connector, and to the surface or wall ofthe second covering module there being connected at least one of asecond electrical connector or a second mechanical connector, said atleast one of said second electrical connector or second mechanicalconnector being complementary to said at least one first electricalconnector or first mechanical connector.
 5. The automated deviceaccording to claim 4, wherein the first covering module at least onesurface or wall includes the first electrical connector and the firstmechanical connector, and the second covering module at least onesurface or wall includes the respective complementary second electricalconnector and the second mechanical connector.
 6. The automated deviceof claim 3, wherein the load-bearing structure of the at least twocovering modules has at least one said electrical connector and at leastone said mechanical connector connected thereto.
 7. The automated deviceaccording to claim 1, wherein the plurality of covering modules furthercomprises a plurality of first covering modules connected in signalcommunication with the control unit and configured for supplying signalsor data representing detections carried out via said at least onecontact sensor or proximity sensor, wherein the control unit isconfigured for identifying a first covering module among said pluralityof first covering modules that supplies said signals or data.
 8. Theautomated device according to claim 7, comprising at least oneelectronic control board to which the at least one contact sensor orproximity sensor of a respective first covering module is connected, theat least one electronic control board being configured for connection insignal communication with the control unit.
 9. The automated device ofclaim 8 wherein the at least one contact sensor or proximity sensor ofat least two first covering modules are connected to the at least oneelectronic control board.
 10. The automated device according to claim 8,wherein said at least one electronic control board is connected to aninner side of the load-bearing structure of one said plurality of firstcovering modules.
 11. The automated device according to claim 1 whereinthe at least one contact sensor or proximity sensor comprises a contactsensor, and wherein the plurality of covering modules each have amultilayered structure including a plurality of superimposed distinctlayers above said load-bearing structure, the plurality of superimposeddistinct layers including said at least one layer of elasticallyyielding material, the at least one layer of elastically yieldingmaterial further comprising: a lower cushioning layer, made of anelastically compressible material and connected to an outer side of theload-bearing structure, the lower cushioning layer positioned below thecontact sensor; and an upper cushioning layer, made of an elasticallycompressible material, the upper cushioning layer positioned above thecontact sensor.
 12. The automated device according to claim 1, whereinthe load-bearing structure is shaped substantially as a rounded orconcave shell, to define a free gap between an inner side thereof and anunderlying part of the movable structure.
 13. The automated deviceaccording to claim 12, further comprising at least one electrical fan,said free gap forming a portion of a ventilation passage for circulationof cooling air forced by said fan.
 14. The automated device according toclaim 1, wherein the load-bearing structure comprises an inner sideincluding stiffening ribs.
 15. The automated device according to claim1, wherein at least one of said contact sensor or proximity sensorfurther comprises an electrically conductive layer including anelectrically conductive fabric.
 16. The automated device according toclaim 15 wherein said at least one of said contact sensor or proximitysensor comprises a contact sensor, wherein said contact sensor furthercomprises a first electrically conductive layer and a secondelectrically conductive layer each including a respective electricallyconductive fabric.
 17. The automated device according to claim 1 whereinthe at least one of a contact sensor or a proximity sensor comprises acontact sensor and a proximity sensor, wherein the plurality of coveringmodules each have a multilayered structure including a plurality ofsuperimposed distinct layers positioned above said load-bearingstructure, the plurality of superimposed distinct layers furthercomprising: said at least one layer of elastically yielding materialfurther comprises an electrically insulating material connected to anouter side of the load-bearing structure; the contact sensor positionedabove said at least one layer of elastically yielding material; anintermediate cushioning layer, comprising an electrically insulatingmaterial and positioned above said contact sensor; the proximity sensorpositioned above said intermediate cushioning layer; and an outercoating layer positioned above the proximity sensor, the outer coatinglayer comprising an electrically insulating material.
 18. The automateddevice according to claim 1, wherein the plurality of covering modulesare connected in signal communication with the control unit and areconfigured for supplying signals or data representing detections carriedout via said at least one of the contact sensor or the proximity sensor,the signals or data comprising at least one of signals or data of arespective first type, representing a contact between the sensorizedcovering and a foreign body, or signals or data of a second type,representing presence of a foreign body within a substantiallypredetermined distance from the sensorized covering, wherein the controlunit is configured for identification of a covering module among theplurality of covering modules that supplies said signals or data, andwherein the control unit is configured for adopting a control strategyof the actuator which depends upon said identification and said type ortypes of signals or data supplied by the identified covering module. 19.The automated device according to claim 18, wherein the control unit isoperable to use the plurality of covering modules as a user interface,operable for a human operator to impart instructions to the control unitfor controlling the actuator.
 20. An automated robot device comprising:a movable structure; an actuator in communication with the movablestructure, the actuator operable to selectively move portions of themovable structure; a control unit in electronic communication with theactuator, the control unit operable to selectively send signals toactuator to selectively move the portions of the movable structure; asensorized covering having a first and a second covering module operableto cover at least a portion of the movable structure, each of the firstand the second covering modules comprising: a load bearing structure; acushioning layer positioned outward of the load bearing structurerelative to the movable structure; a contact sensor positioned outwardof the cushioning layer relative to the movable structure, the contactsensor operable to detect a physical impact of the sensorized coveringwith a foreign object and send an impact signal to the control unit; aproximity sensor positioned outward of the contact sensor relative tothe movable structure, the proximity sensor operable to detect thepresence of a foreign object within a predetermined distance from thesensorized covering and send a detection signal to the control unit; anouter coating layer substantially covering the proximity sensor; aperipheral wall positioned to oppose a complementary opposing wall onthe first or the second covering module; a first mechanical connector ora second mechanical connector connected to the peripheral wall, thesecond mechanical connector complementary to the first mechanicalconnector, the first and the second mechanical connectors operable toremovably connect the first covering module to the second coveringmodule.